Product Introduction

Electrical Contacts Machining Assembly represents the modern standard for precision electrical connections. These high-performance contacts utilize noble metal materials such as silver-nickel alloys and palladium-gold composite coatings, achieving ±0.01mm tolerance control through precision stamping, CNC machining, and automated assembly processes. The resulting maintenance-free solutions offer:

· Ultra-low contact resistance (<5mΩ)

· 100% corrosion resistance (suitable for marine/tropical environments)

· 50% reduced mating wear compared to traditional contacts

Ideal for critical applications including EV high-voltage relays, industrial robot servo systems, and data center precision power distribution, these contacts deliver up to 10A/mm² current density while eliminating welding risks and reducing contact bounce by 90%

Electrical Contacts Machining Assembly

Employs a multi-process strategy tailored to material and application demands.

Resistance Brazing

Ideal for low-voltage electrical contacts (≤48V DC), such as silver-plated copper connectors in medical devices or automotive sensors. By controlling current flow to heat only the joint area, we achieve ≤5℃ temperature precision, preventing oxidation or deformation while maintaining ≥95% IACS conductivity.

Projection Welding

Automates the bonding of copper-silver composite contacts, leveraging workpiece protrusions for instant, high-strength joints (≥500 MPa) with a 40% faster cycle time than traditional methods. Critical for automotive relays, circuit breakers, and other components requiring resilience under extreme temperatures (-40℃~125℃).

Spot Welding Assembly

Supports rapid prototyping of small-batch orders, achieving 0.01mm precision and 99.95% yield rates for dissimilar metal joints (e.g., copper-nickel, silver-stainless steel) in complex structures like new energy batteries and sensors.

Quality is non-negotiable in our Electrical Contacts Machining Assembly. Copper alloy substrates (C11000/C26000) are UL-certified, featuring silver-plated layers (≥ 5 μm) that comply with ROHS/REACH regulations. Every low-voltage electrical contact undergoes dimensional checks via CMM (with a tolerance of ±0.005 mm) and contact resistance testing (≤0.5 mΩ for spot welding assemblyjoints). For projection-welded contacts, we validate tensile strength (≥500 MPa) and salt spray resistance (72h corrosion-free).

Multi-process Welding and Welded AssemblieslogoElectrical Contacts Machining Assembly

Our products Service

Automotive Electronics

Delivers projection-welded relay contacts for ≥500 MPa strength and -40℃~125℃ resilience, alongside resistance-brazed sensor contacts for microstructures (0.5mm diameter) with ≤0.3 mΩ resistance.

Industrial Controls

Relies on spot-welded circuit breaker contacts for dissimilar metal (copper-nickel) joints, improving arc erosion resistance by 30%.

Renewable Energy

PV inverters benefit from projection-welded high-current (≥100A) contacts with ≤0.2 mΩ resistance, while energy storage battery contacts leverage resistance brazing for low-heat impact, critical for lithium-ion battery environments

Our technical core team boasts over 30 years of experience in the electrical industry. Beyond delivering compliant products, we provide cost-reduction and efficiency-enhancement solutions, along with access to the latest industry innovations. We adhere to a rapid-response principle, offering free samples within 1–2 days, prototype samples (including new mold development and sample production) within 20–30 days, and mass production deliveries within 15–20 days (after order confirmation and payment). Additionally, we ensure reliable credit support and swift after-sales service.

Common application fields

1. High-voltage electrical system of new energy vehicles

In electric vehicle (EV) high-voltage relays and battery management systems (BMS), Resistance Brazing Electrical Contacts achieve metallurgical bonding between copper substrates and silver alloy coatings through localized heating, ensuring 30% higher contact strength, resistance to transient overloads (200°C/1000 cycles), and contact resistance reduced to <2mΩ, suitable for 800V fast-charging platforms.

2. Industrial automation and robot control

Industrial robot servo drives and PLC control modules utilize Low Voltage Electrical Contacts paired with Spot Welding Assembly for non-contact connection of 0.02mm ultra-thin coated contacts, achieving dynamic contact resistance <3mΩ, suitable for micro-current (<1A) applications, 40% lower temperature rise, and 1 million cycles mechanical durability with IP67 protection.

3. We are the largest Business expert

erospace relays and onboard power systems employ Projection Welding for precise joining of palladium-gold composite contacts with titanium carriers, enhancing contact stability by 50%, resistance to vibration shocks (100g acceleration), and extreme temperature ranges (-55°C to 125°C), certified to MIL-STD-883H military standards for satellite, missile, and other high-reliability applications.

4. consumer electronics and medical precision equipment

Miniature switches, wearable devices, and surgical robots utilize Spot Welding Assembly for precise 0.1mm-pitch contact connections, eliminating solder dross and oxide layers, achieving signal transmission error rates <10⁻⁹, low insertion/extraction forces (<0.5N), and zero bounce, suitable for frequent switching scenarios, compliant with RoHS and ISO 13485 medical certifications.

why choose our Electrical Contacts Machining Assembly